Texas Instruments AN-1455 LM5072 Evaluation Board (Rev. A) User guide

Brand: Texas Instruments

Model: AN-1455 LM5072 Evaluation Board (Rev. A)

Category: Voltage regulators

Type: User guide

Texas Instruments AN-1455 LM5072 Evaluation Board (Rev. A) is a low-cost, fully IEEE 802.3af compliant Power over Ethernet (PoE) power supply, capable of operating with both PoE and auxiliary (AUX) power sources. It features the LM5072 PoE Powered Device (PD) interface and controller integrated circuit (IC) configured in the versatile flyback topology. The evaluation board has a single isolated 3.3V output, and can support dual isolated 5V and 3.3V outputs or non-isolated outputs.

User's Guide

SNVA154A–March 2006–Revised May 2013

AN-1455 LM5072 Evaluation Board

1 Introduction

The LM5072 evaluation board is designed to provide a low cost, fully IEEE 802.3af compliant Power over

Ethernet (PoE) power supply, capable of operating with both PoE and auxiliary (AUX) power sources. The

evaluation board features the LM5072 PoE Powered Device (PD) interface and controller integrated circuit

(IC) configured in the versatile flyback topology.

2 Features of the LM5072 Evaluation Board

• Single Isolated 3.3V output (see Figure 1)

• Dual Isolated 5V and 3.3V outputs supported (see Figure 15)

• Non-Isolated outputs supported (see Figure 16)

• Maximum output current 3A

• Input voltage range for maximum output current (as configured):

– With the installed wide-voltage-range EP13 transformer

– PoE input voltage range: 38 to 60V

– FAUX input voltage range: 24 to 60V

– RAUX input voltage range: 16 to 60V

– With the optional, efficiency-optimized EP13 transformer

– PoE input voltage range: 38 to 60V

– FAUX input voltage range: 24 to 60V

– RAUX input voltage range: 24 to 60V

• Measured maximum efficiency:

– With the installed wide-voltage-range EP13 transformer

– DC to DC converter efficiency: 81% at 3A

– Overall efficiency (including diode bridge): 78.5% at 3A

– With the optional, efficiency-optimized EP13 transformer

– DC to DC converter efficiency: 84% at 3A

– Overall efficiency (including diode bridge): 81.5% at 3A

• Board Size: 2.75 x 2.00 x 0.66 inches

• Operating frequency: 250 kHz

• PoE input under-voltage lockout (UVLO) release: 39V nominal

• PoE input UVLO hysteresis: 7V nominal

This application note focuses on the evaluation board. Please refer to the LM5072 Integrated 100V Power

Over Ethernet PD Interface and PWM Controller with Aux Support (SNV437) data sheet for detailed

information about the complete functions and features of the LM5072 IC.

All trademarks are the property of their respective owners.

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A Note about Input Potentials

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3 A Note about Input Potentials

The LM5072 is designed for PoE applications that are typically -48V systems, in which the notations GND

and -48V normally refer to the high and low input potentials, respectively. However, for easy readability,

the LM5072 data sheet was written in the positive voltage convention with positive input potentials

referenced to the VEE pin of the LM5072. Therefore, when testing the evaluation board with a bench

power supply, the negative terminal of the power supply is equivalent to the PoE system’s -48V potential,

and the positive terminal is equivalent to the PoE system ground. To prevent confusion between the data

sheet and this application note, the same positive voltage convention is used herein.

4 A Note About the Maximum Power Capability

While the LM5072 provides a fully IEEE 802.3af compliant PD solution, it is also capable of supporting

higher power level applications with an input current up to 700 mA. However, this evaluation board is

designed for IEEE 802.3af compliant PD power levels less than 12.95W. This power limitation is mainly

due to the use of appropriately rated devices like the power transformer and power switch MOSFET,

which do not support higher power levels. It should be noted that when using the LM5072 at elevated

power levels, the thermal environment must be carefully considered.

No power conversion is 100% efficient. It should be noted that conversion efficiency lowers the amount of

power that can be delivered to the load to levels significantly below 12.95W. For example, 75% efficiency

limits the power delivered to 9.7W. Conversion efficiency must also be taken into account when

calculating board input current.

Finally, when configured for front auxiliary operation, the maximum power deliverable may be limited by

the hot swap MOSFET’s DC current limit function. This is especially true at lower input voltages. The

current limit can be adjusted via a single resistor on the DCCL pin.

5 Schematic of the Evaluation Board

Figure 1 shows the schematic of the LM5072 evaluation board. See Appendix A for the Bill of Materials

(BOM).

Figure 1. Schematic of the LM5072 Evaluation Board

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PoE

Load

S/N

xxxx

BR1

BR2

RAUX

FAUX

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Connection and Proper Test Methods

6 Connection and Proper Test Methods

Figure 2. LM5072 Evaluation Board Connections

Figure 2 shows the connections for the LM5072 evaluation board.

The LM5072 evaluation board has the following four ports for connections.

• J1, the RJ45 connector for PoE input

• J2, a PJ102A power jack, for Front Auxiliary (FAUX) input (also accessible with posts P1 and P2

located immediately behind the jack)

• J3, the other PJ102A power jack, for Rear Auxiliary (RAUX) input (also accessible with posts P3 and

P4 immediately behind the jack)

• The 3.3V output port accessible with posts J4 and J5

For the PoE input, two diode bridges (BR1 and BR2) steer the current to the positive and negative supply

pins of the LM5072. For both FAUX and RAUX inputs, the higher potential input voltages should feed into

the center pins of the PJ102A jacks, or to P1 and P3, respectively. It should be pointed out that P2 and

P4, the returns for the FAUX and RAUX inputs, should not be interchanged because they do not represent

the same potential in the circuit. The RAUX pin is not reverse protected, and an additional reverse

blocking diode will be required for complete RAUX input reverse protection.

For the output connection, the load can be either a passive resistor or active electronic load. Attention

should be paid to the output polarity when connecting an electronic load. Use of additional filter capacitors

greater than 20 µF total across the output port is not recommended unless the feedback loop

compensation is adjusted accordingly.

Sufficiently large wire such as AWG #18 or thicker is required when connecting the source supply and

load. Also, monitor the current into and out of the circuit board. Monitor the voltages directly at the board

terminals, as resistive voltage drops along the connecting wires may decrease measurement accuracy.

Never rely on the bench supply’s voltmeter or ammeter if accurate efficiency measurements are desired.

When measuring the dc-dc converter efficiency, the converter input voltage should be measured across

C4, as this is the input to the converter stage. When measuring the evaluation board overall efficiency

(which is more relevant), both input and output voltages should be read from the terminals of the

evaluation board.

7 Source Power

To fully test the LM5072 evaluation board, a DC power supply capable of at least 60V and 1A is required

for the PoE input. For the auxiliary source power, either FAUX or RAUX, use a DC power supply capable

of 3A. Use the output over-voltage and over-current limit features of the bench power supplies to protect

the board against damage by errant connections.

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Loading / Current Limiting Behavior

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8 Loading / Current Limiting Behavior

A resistive load is optimal, but an appropriate electronic load specified for operation down to 2.0V is

acceptable. The maximum load current is 3.3A. Exceeding this current at low input voltage may cause

oscillatory behavior as the part will go into current limit mode. Current limit mode is triggered whenever the

average current through the PoE connector exceeds 440 mA (default nominal). The current limit can be

programmed to any desired level up to 800 mA by selecting a resistor value for R23 (see the LM5072

datasheet for further details). If current limit is triggered, the switching regulator is automatically disabled

by discharging the softstart capacitor C26 through the SS pin. The module is then allowed to restart, but

the unit will operate in an automatic re-try (hiccup) mode as long as the over-current condition remains.

Switching regulator shut down during a fault condition such as current limit can be delayed by adding

additional filtering capacitance to the nPGOOD pin.

9 Power Up

It is suggested to apply PoE power first. During the first power up, the load should be kept reasonably low.

Check the supply current during signature and classification modes before applying full power. During

signature mode, the module should have the I-V characteristics of a 25 kΩ resistor in series with two

diodes. During classification mode, current draw should be about 700µA at 16V; the RCLASS pin is left

open, defaulting to class 0. If the proper response is not observed during both signature and classification

modes, check the connections closely. If no current is flowing it is likely that the set of conductors feeding

PoE power have been incorrectly installed.

Once the proper setup has been established, full power can be applied. A voltmeter across the output

terminals J4 (+3.3V) and J5 (3.3V RTN), will allow direct measurement of the 3.3V output line. If the 3.3V

output voltage is not observed within a few seconds, turn the power supply off and review connections.

A final check of efficiency is the best way to confirm that the unit is operating properly. Efficiency

significantly lower than 80% at full load indicates a problem.

After proper PoE operation is verified, the user may apply auxiliary power to the FAUX or RAUX inputs. It

is recommended that the application of the auxiliary power follow the same precautions as those taken

when applying PoE. If no output voltage is observed, it is likely that the auxiliary power feed polarity is

reversed. After successful operation is observed in both FAUX and RAUX modes, full power testing can

begin.

10 PD Interface Operating Modes

When connecting into the PoE system, the evaluation board’s Powered Device interface will go through

the following operating modes in sequence: PD signature detection, power level classification (optional),

and application of full power. Refer to the SNV437 data sheet and IEEE 802.3af for detailed information

about these operating modes.

11 Signature Detection

The 25 kΩ PD signature resistor is integrated into the LM5072 IC. The PD signature capacitor is

implemented with a 100 nF capacitor at C27 or C29, depending on the auxiliary input configuration.

It should be noted that when either FAUX or RAUX power is applied first, it will not allow the Power

Sourcing Equipment (PSE) to identify the PD as a valid device because the auxiliary voltage will cause the

current steering diode bridges to be reverse biased during detection mode. This prevents the PSE from

applying power, so the evaluation board will only draw current from the auxiliary source.

12 Classification

PD classification is implemented with R22. The evaluation board is set to the default Class 0 by leaving

the RCLASS pin open (R22 position not populated). To activate a specific class instead of Class 0, install

R22 according to the following table.

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Input UVLO and UVLO Hysteresis

Class P

MIN

MAX

CLASS

(MIN) I

CLASS

(MAX) R22 Selection

0 0.44W 12.95W 0mA 4mA Open

1 0.44W 3.84W 9mA 12mA 130Ω

2 3.84W 6.49W 17mA 20mA 71.5Ω

3 6.49W 12.95W 26mA 30mA 46.4Ω

4 Reserved Reserved 36mA 44mA 31.6Ω

13 Input UVLO and UVLO Hysteresis

The input Under Voltage Lock-Out (UVLO) is an integrated function of the LM5072. The UVLO release

threshold is set to approximately 38.5V (at the pins of the IC) and the UVLO hysteresis is approximately

7V.

14 Inrush and DC Current Limit Programming

The LM5072 allows the user to independently program the inrush and DC current limits of the internal Hot

Swap MOSFET. The evaluation board sets the inrush limit to the default 150 mA by leaving R19

unpopulated, and the DC current limit to the default 440 mA by leaving the DCCL pin open (R23 not

populated). In applications where it is desirable to adjust these values, install R19 and R23, respectively,

according to the recommendations in the LM5072 datasheet. Please note that by leaving the DCCL pin

open, the default 440 mA DC current limit will be elevated to 550 mA during FAUX operation. When R23

is used to program the DC current limit, it applies to both PoE and FAUX power modes, and it should be

considered a “firm limit”, that is, independent of operating mode.

15 FAUX Power Option

For the FAUX power option, the ICL_FAUX pin of the LM5072 senses the FAUX input voltage through D7

and R6. When the current flowing into the ICL_FAUX pin is greater than 50 µA at 8.5V nominal, it will

establish a state at the ICL_FAUX pin that forces UVLO release in order to allow operation at an auxiliary

input voltage as low as 18V (17V seen by the VIN pin of the LM5072 IC). One should not try to use the

ICL_FAUX as a stable, accurate UVLO threshold, the front auxiliary supply should pull the pin up well past

the voltage and current thresholds.

It should be pointed out that the minimum operative FAUX input voltage for the maximum output current is

24V. This is mainly limited by the default 540 mA FAUX input DC current limit of the LM5072’s internal hot

swap MOSFET. By lowering the FAUX input voltage, the input current will exceed the said limit unless the

output current is reduced accordingly.

If the FAUX power option is not used in a new design, delete C1, D3, D7, R6, and J2 from the circuit to

reduce the BOM cost.

16 RAUX Power Option

For the rear auxiliary power option, the RAUX pin of the LM5072 senses the RAUX input voltage through

R13. When the current flowing into the RAUX pin is greater than 20 µA at 2.5V nominal, it will establish a

state at the RAUX pin that forces switching regulator controller operation at input voltages as low as 10V

(9V seen by the pins of the LM5072 IC). When the current flowing into the RAUX pin is greater than 250

µA at 6V nominal, which is the preset configuration of the evaluation board, auxiliary dominance is

selected. During auxiliary dominance, the RAUX power source will always supply the current to the PD

regardless if PoE power is present or not. This is accomplished by forcing a shut down of the hot swap

MOSFET. If the PSE has implemented DC Maintain Power Signature, it will remove the 48V supply thus

freeing up power to be allocated to other ports. If only AC Maintain Power Signature is implemented, the

PSE may or may not remove power. Note that auxiliary non-dominance does not imply PoE dominance.

PoE dominance is very difficult to achieve without additional circuitry. Contact Texas Instruments for a

schematic of a robust PoE dominant solution.

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Auxiliary Dominant in RAUX Power Option

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Because the LM5072’s input hot swap feature is not applicable to the RAUX input, two 2Ω resistors (R1

and R2) in parallel are used to achieve transient protection. Unlimited inrush currents can wear on board

traces, connector contacts, and various board components, as well as create dangerous transient

voltages. Nevertheless, these two resistors will cause power loss in the RAUX power mode, and they also

reduce the effective RAUX input voltage level sensed by the VIN pin of the LM5072. The resistors should

be made as large as is practical for the application. But, with a low RAUX input voltage (<16V), R1 and R2

may need to be reduced to a lower value.

During RAUX operation, the hot swap MOSFET is turned off. Consequently, the substrate of the IC no

longer has a low impedance path to power return. It is advised that the user remove C27 and populate

C29. A capacitor across the hot swap MOSFET will act as both the signature capacitor and a high

frequency short for any substrate noise.

If the RAUX power option is not used in a new design, delete C3, D1, D2, R1, R2, R13, R29 and J3 from

the circuit to lower the BOM cost.

17 Auxiliary Dominant in RAUX Power Option

The evaluation board is populated for auxiliary dominance in the RAUX power option. This is achieved by

selecting 4.99 kΩ for R13. In applications where auxiliary dominance is not desirable, change the installed

R13 to a higher value. Please refer to the LM5072 SNV437 data sheet for assistance in selecting this

value.

18 Auxiliary Input “OR-ing” Diode Selection

Special attention should be paid to the selection of D1 and D3. They need not be high speed diodes

because there is no switching action during operation associated with these components, but they should

be low reverse leakage current devices. Otherwise, the leakage current during operation may create a

false signal at the ICL_FAUX pin, the RAUX pin, or both, as if the circuit is powered from the FAUX or

RAUX source. Leakage current into the ICL_FAUX pin may also corrupt inrush current programming, if

implemented. Most diode and transistor data sheets provide information on the maximum leakage current

at both 25°C and 125°C, although the data for the intermediate temperatures are not often supplied. It can

be approximated that the leakage current doubles for every 10°C rise in temperature.

The junction temperature of these devices should not reach 125°C because the only dissipation inside

these devices is caused by the leakage current. Therefore, it is not necessary to select the devices based

on the maximum leakage current specified at 125°C. The evaluation board design considered 55°C as the

maximum junction temperature of these devices, which is acceptable for most PoE applications. Simple

circuit adjustments can be made if higher leakage currents are expected.

Resistors R29 and C1 (note that a resistor is installed at the C1 location on the evaluation board to

achieve the function similar to R29’s) are both 24.9 kΩ, providing paths for the leakage currents of D1 and

D3, respectively. These two resistors are meant to sink all of the leakage current from the diodes and

prevent false states at the ICL_FAUX and RAUX pins. Please see the LM5072 SNV437 data sheet for

more details about the selection of these two resistors.

19 Flyback Converter Topology

The dc-dc converter stage of the LM5072 evaluation board features the flyback topology, which employs

the minimum number of power components to implement an isolated power supply at the lowest possible

cost.

A unique characteristic of the flyback topology is its power transformer. Unlike an ordinary power

transformer that simultaneously transfers the power from the primary to the secondary, the flyback

transformer first stores the energy in the transformer core while the main switch is turned on, then

releases the stored energy to the load during the rest of the cycle. When the stored energy is not

completely released before the main switch is turned on again, it is said that the flyback converter

operates in continuous conduction mode (CCM). Otherwise, it is in discontinuous conduction mode

(DCM).

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Factors Limiting the Minimum Operating Input Voltage

Major advantages of CCM over DCM include (i) lower ripple current and ripple voltage, requiring smaller

input and output filter capacitors; and (ii) lower RMS current, thus reducing the conduction losses. To keep

the flyback converter in CCM at light load, the transformer’s primary inductance should be designed as

large as is practical.

Major drawbacks of CCM, as compared to DCM, are (i) the presence of the right-half-plane zero, which

may limit the achievable bandwidth of the feedback loop, and (ii) the need for slope compensation to

stabilize the feedback loop at duty cycles greater than 50%.

The flyback topology can have multiple secondary windings for several isolated outputs. One or more of

these secondary channels are normally utilized internally by the converter itself to provide necessary bias

voltages for the controller.

The evaluation board uses a small power transformer having a primary inductance of 32 µH. This is a

compromise made to allow the small transformer to operate over a wide input voltage range from 13V to

60V. However, with this transformer, the flyback converter runs in CCM at full load for input voltages lower

than 42V, and in DCM for higher input voltages or light loads. The LM5072’s built-in slope compensation

helps stabilize the feedback loop when the duty cycle exceeds 50% during low input voltage operation.

A transformer winding is used to provide the bias voltage (V

) to the LM5072 IC. Although the LM5072

controller includes an internal startup regulator which can support the bias requirement indefinitely, the

transformer winding produces an output about 2V higher than the startup regulator output, thus shutting

off the startup regulator and reducing the power dissipation inside the IC. Given the low current limit value

(15 mA nominal) of the high voltage startup regulator, the V

line is not meant to be a linear regulator for

external loads.

20 Factors Limiting the Minimum Operating Input Voltage

The LM5072 supports operation with low voltage auxiliary power sources. The minimum FAUX voltage is

24V for the maximum output current. It can be reduced to 18V if the output current is reduced to 2A. The

voltage drop caused by the FAUX input OR-ing diode D3 reduces the VIN pin potential to 17V. This is

because at lower FAUX input voltages the maximum power that can be delivered to the load will be

greatly reduced by the hot swap MOSFET’s current limit function. This is one of the drawbacks of FAUX

operation, though DC current limit can be adjusted by adding / changing the value of the DCCL resistor.

The minimum RAUX voltage of the evaluation board is 16V (voltage drops caused by the inrush limit

resistors R1 and R2 and the RAUX input OR-ing diode D1 reduce the VIN pin potential to about 15V),

although the LM5072 can function with a minimum of 9V seen at VIN. The 13V RAUX operating voltage

limit is mainly determined by three factors; the value of the RAUX inrush current limit resistor R1 and R2,

the flyback power transformer design, the values of the current sense resistors R14 and R15, and mainly

the dropout of the startup regulator.

The installed R1 and R2 are 2Ω resistors. Under full load conditions, these two resistors significantly

reduce the effective RAUX voltage seen by the DC-DC converter stage. In order to operate the evaluation

board at a lower input voltage, it is required to reduce R1 and R2 to 1Ω or lower values.

The installed EP13 type power transformer (DA2257-AL or DCT13EP-U12S005) is a low cost, area

efficient solution to operate with a wide auxiliary input voltage range. However, the small cross-sectional

area of the EP13 magnetic core also limits the maximum flux it can support. To use such a small

transformer from 16V to 60V input under the full load condition, a compromise between the minimum

operating input voltage and maximum inductance of the transformer must be made such that the peak

current at 16V input will not cause the peak flux density to exceed 3000 Gauss (saturation). A drawback of

this low cost solution is that the RMS current flowing through the dc-dc converter stage is increased and

the efficiency of the dc-dc converter suffers by about 3%.

Replacing the installed transformer with the optional power transformer DA2383-AL from Coilcraft

improves the efficiency, but the minimum operating input voltage will be limited to 24V. To use this

optional transformer for lower input voltage, the load level should be scaled down accordingly, as shown in

Figure 3.

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x L

x (V

+ V

)

R14 x R15

1.8 x D

max

R14 + R15

2 x D

max

- 1

x 10

-4

10 20 30 40 50 60

(V)

1.0

1.5

2.0

2.5

3.0

3.5

MAX I

OUT

(A)

DA2257-AL or

DCT13EP-

U125005

DA2383-AL

Factors Limiting the Minimum Operating Input Voltage

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Figure 3. Maximum Load Current vs. Minimum Input Voltage as Limited by Different EP13 Type Power

Transformers

To optimize efficiency over the maximum input voltage range of 10.5V to 60V (9V min seen at the VIN pin,

after R1 and R2 are replaced with 1Ω), a larger magnetic core like the EFD20 should be used. The EFD20

core has adequate cross-sectional area to handle the peak currents observed with a 10.5V input.

The effects of the current sense resistors R14 and R15 also limit the minimum RAUX input operating

voltage. The LM5072’s internal slope compensation stabilizes the feedback loop of the dc-dc converter

when the duty cycle exceeds 50% for input voltages lower than 22V. However, the relative magnitude of

the slope compensation is inversely proportional to the values of R14 and R15. The maximum values of

R14 and R15 are governed by the following relation:

(1)

where

max

is the duty cycle at the minimum AUXILIARY input voltage;

the switching frequency, in kHz

the flyback transformer primary inductance, in µH

the transformer’s primary to secondary turns ratio

the output voltage, in volts

the forward drop of the output diode D5, in volts

Selecting 0.30Ω for both R14 and R15 will allow a minimum operating voltage of 16V. For lower RAUX

input voltages, Dmax is greater and hence R14 and R15 must be reduced accordingly. However, smaller

resistors increase the effect of internal slope compensation. Increasing the slope compensating makes the

feedback loop appear more like voltage mode than current mode. This in turn requires the use of a low

ESR capacitor for C16, rather than the low cost capacitor initially installed on the evaluation board.

In summary, the 16V minimum operating RAUX input voltage of the evaluation board is limited by the low

cost solution, and also by the dropout of the startup regulator. In order to use the evaluation board with a

lower RAUX source, the power transformer T1, the output capacitor C16, R14, and R15 should be

modified, in addition to the installation of D2.

D2 should be installed whenever the voltage at the VIN pin is less than 15V. This ensures the V

regulator has enough voltage to start given its relatively high drop out requirement. One must also be

careful not to violate the VCC pin’s absolute maximum voltage rating under this configuration. Accordingly,

a 15V nominal auxiliary supply may be difficult to design for, as it will require the installation of D2 and

violate the pin’s absolute maximum rating. Additional circuitry may be required, or the selection of a

different auxiliary input voltage.

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Performance Characteristics

21 Performance Characteristics

21.1 PoE Input Power-up Sequence

The high level of integration designed into the LM5072 allows all power sequencing communications to

occur within the IC. Very little system management design is required by the user. The power up

sequence is as follows. Note that the RTN pin (IC pin 8) is isolated from the +3.3V RTN output pin of the

board:

1. Before power-up, all nodes in the non-isolated section of the power supply remain at high potential

until UVLO is released and the drain of the internal hot swap MOSFET is pulled down to VEE (IC pin

7).

2. The V

regulator powers up during the inrush sequence. During V

regulator startup, it draws current

on the order of 20mA, but this will likely not be noticed by the user. Once the RTN pin of the IC drops

below 1.5V (referenced to VEE), and the gate of the hot swap MOSFET rises, power good is asserted

by pulling the nPGOOD pin low.

3. Once power good has been asserted, the SS (Soft-Start) pin is released. The SS pin will rise at a rate

equal to the SS current source, typically 10µA, divided by the SS pin capacitance, C26.

4. As the switching regulator achieves regulation, the auxiliary winding will raise the V

voltage to about

11V, thus shutting down the internal regulator and increasing efficiency.

Figure 4 shows the voltage at the RTN pin (referenced to VEE), output voltage V

OUT

and input current

during a normal startup sequence. The RTN voltage gradually drops as the input current charges the input

capacitors. When the charging process is completed, the RTN voltage drops to below 1.5V, followed by

the soft start of the converter.

Figure 5 shows the V

voltage during startup. The V

of about 8V is first produced by the internal startup

regulator. When the output regulation is established, V

is elevated to about 11V through cross-

regulation.

Horizontal Resolution: 5 ms/Div.

Trace 1: VOUT, 2V/Div.

Trace 2: RTN pin (referenced to VEE), 20V/Div.

Trace 3: Input Current, 200 mA/Div.

Figure 4. Normal PoE input Startup Sequence

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Performance Characteristics

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Horizontal Resolution: 5 ms/Div.

Trace 1: VOUT, cross-regulating VCC after output regulation is established. 2V/Div.

Trace 2: VCC, first regulated by startup regulator at 7.6V, then elevated by auxiliary winding to 11V. 2V/Div.

Trace 3: Input Current, 0.5A/Div.

Figure 5. VCC During Startup

21.2 Auxiliary Input Power-up Sequence

The FAUX input power up sequence is similar to that of the PoE input, with the exception that the 38V

UVLO release threshold is overridden when the ICL_FAUX pin is pulled up.

The RAUX input power up sequence is simpler:

1. Auxiliary application quickly charges the input capacitors. There should not be any overshoot observed

as the series resistors should limit the inrush.

2. When the V

regulator establishes 7.6V, soft start of the PWM controller begins.

3. As the switching regulator achieves regulation, the auxiliary winding will raise the V

voltage to about

10V, thus shutting down the internal regulator and increasing efficiency.

Figure 6 and Figure 7 shows the FAUX and RAUX input power up sequence, respectively.

Horizontal Resolution: 5 ms/Div.

Trace 1: VOUT, 2V/Div.

Trace 2: VCC, 5V/Div.

Trace 3: Input Current, 0.5A/Div.

Figure 6. Normal FAUX input Startup Sequence

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Performance Characteristics

Horizontal Resolution: 5 ms/Div.

Trace 1: VOUT, 2V/Div.

Trace 2: VCC, 5V/Div.

Trace 3: Input Current, 0.5A/Div.

Figure 7. Normal RAUX input Startup Sequence

Figure 8 shows the normal 3.3V output voltage startup, along with the SS pin for reference.

Horizontal Resolution: 1 ms/Div.

Trace 1: VOUT, 1V/Div.

Trace 2: SS pin voltage (referenced to RTN), 1V/Div

Trace 3: Input current (AC coupled), 200 mA/Div

Figure 8. Output Voltage Vout (+3.3V) Soft-start Detail

21.3 Output Dead Short Fault Response

The evaluation board survives the output dead short condition by running into a re-try mode (hiccup).

Applying a dead short to the +3.3V line causes a number of protection mechanisms to occur sequentially.

They are:

1. The feedback signal increases the duty cycle in an attempt to maintain the output voltage. This initiates

cycle-by-cycle over-current limiting which turns off the main switch when the current sense (CS) pin

exceeds the current limit threshold.

2. The current in the internal hot swap MOSFET rises until it is current limited around 440 mA. Some

overshoot in the current will be observed, as it takes time for the current limit amplifier to react and

change the operating mode of the MOSFET.

3. Because linear current limit is accomplished by driving the MOSET into the saturation region, the drain

voltage (RTN pin) rises. When it reaches 2.5V with respect to VEE, power good is de-asserted and the

nPGOOD pin rises in voltage.

4. The de-assertion of power good causes the discharge of the softstart capacitor, which disables all

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Performance Characteristics

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switching action in the dc-dc converter.

5. Once the switching stops, the current in the internal MOSFET will decrease and the drain voltage will

fall back below 1.5V with respect to VEE. When power good is re-asserted, the dc-dc converter will

automatically restart with a new softstart sequence.

Figure 9 shows the cycle-by-cycle peak current limit providing the over-current protection under output

short-circuit condition. The short-circuit condition causes a large over current such that it intends to

saturate the power transformer. Consequently, a large peak current of about 4.33A is produced in the

primary circuit. This large peak current causes the current-sense voltage at CS pin to exceed the peak

limit threshold (>0.5V). Therefore the PWM duty cycle is cut short, leading to a limited input current (the

average current of the current pulses) at about 0.34A.

Horizontal Resolution: 1 µs/Div.

Trace 1: Voltage at the CS pin, 200 mV/Div.

Trace 2: Input Current, 0.5A/Div.

Vin=48V. Iin=0.34A

Figure 9. Cycle-by-Cycle Peak Current Limit Protection Under Output Short-Circuit Condition

Figure 10 shows the over-current protection by the hot swap MOSFET’s dc current limit under the output

short circuit condition. The circuit operates in the FAUX power configuration, and the FAUX input voltage

is set to 24V. The input current will exceed the 440 mA DC current limit of the hot swap MOSFET, and

causes the voltage at the RTN pin to rise rapidly. It also discharges the soft start capacitor C26 connected

to the SS pin, and the circuit enters the automatic retry mode until the over-current condition is removed.

The voltage at the SS pin is observed to rise quickly as the LM5072 reacts to the fault. This is because

the internal soft-start circuitry is referenced to RTN, while all scope measurements are referenced to VEE.

Horizontal Resolution: 5 ms/Div.

Trace 1: RTN pin voltage (referenced to VEE), 2V/Div.

Trace 2: Softstart pin (referenced to VEE), 5V/Div.

Trace 3: Input current, 0.5A/Div.

FAUX input=24V

Figure 10. Shorted Output Fault Condition / Automatic Re-try

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Performance Characteristics

21.4 Step Response

Figure 11 shows the step load response at Vin = 48V.

Horizontal Resolution: 0.2 ms/Div.

Trace 1: Output voltage (AC coupled), 200 mV/Div.

Trace 2: Output current (DC coupled), 0.5 A/Div.

Figure 11. Regulator Response to Step Load

21.5 Ripple Voltage Current

Figure 12 shows the output ripple voltage and input ripple current for 48V input voltage and 3.3A output.

The input ripple current is reduced to less than 5 mA pk-pk by the input filter inductor.

Horizontal Resolution: 0.2 ms/Div.

Trace 1: Output voltage (AC coupled), 20 mV/Div.

Trace 2: Input current (AC coupled), 50 mA/Div.

Vin=48V, Iout=3.3A

Figure 12. Ripple Currents and Voltages

21.6 FLYBACK Transformer Waveforms

Figure 13 and Figure 14 show typical flyback transformer waveforms: the drain to source voltage of the

main switch Q1 and the reverse voltage of the rectifier diode D5, respectively, at 48V input voltage and

3.3A output.

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Horizontal Resolution: 1 µs/Div.

Trace 1: Drain to source voltge of main switch Q1, 50V/Div.

Vin=48V, Iout=3.3A

Figure 13. Flyback Transformer Waveforms

Horizontal Resolution: 1 µs/Div.

Trace 1: Reverse voltage across output rectifier diode D5, 5V/Div.

Vin=48V, Iout=3.3A

Figure 14. Flyback Transformer Waveforms

22 Reconfiguration of the Evaluation Board for 3.3V And 5V Dual Outputs

The standard evaluation circuit can be easily reconfigured into a 2A 3.3V and 0.6A 5.5V dual output power

supply. To reconfigure the board for dual output, populate the components for the 5.5V output rail as

shown in Figure 15. These components are listed in Section A.1.

23 Reconfiguration of the Evaluation Board for Non-Isolated Output

For applications where output isolation is not required, the non-isolated version of the evaluation board

can be used to reduce the BOM cost. Reconfiguration of the circuit board to the non-isolated version can

be accomplished in the following four steps:

1. Delete the unused parts from the circuit board as well as the BOM: C20, C22, C25, C28, R7, R11,

R16, R17, R24, U2 and U3.

2. Connect test points P5 and P6 with a bus wire of AWG 26.

3. Short C28 pads by installing a 0Ω resistor of R2010 size, or by soldering a piece of AWG 26 bus wire.

4. Change C30 to 3.3 nF, C31 to 1.0 nF and R20 to 10 kΩ.

Figure 16 shows the schematic for non-isolated circuit with a single 3.3V output. Similar changes also

apply to the dual output version.

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A Note For Using The Efficiency Optimized EP13 Power Transformer DA2383

Figure 15. The Schematic for Dual Outputs

Figure 16. The Schematic for Non-Isolated Output

24 A Note For Using The Efficiency Optimized EP13 Power Transformer DA2383

Please note that the DA2383 is a single output transformer. When using a DA2383 to obtain better

efficiency (See Figure 3 for the applicable load and AUX input voltage levels), also remember to connect

D5's cathode to DA2383's pin 9 with a short jumper wire. This is because the secondary winding of

DA2382 uses Pins 6 through 9 of the transformer bobbin, unlike DA2257 that only uses of Pins 7 and 8 for

the secondary winding. The maximum converter stage efficiency at 3.3A will be expected to be greater

than 84%.

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Appendix A LM5072 Evaluation Board Bill of Materials

Table 1. LM5072 Evaluation Board Bill of Materials

ITEM PART NUMBER DESCRIPTION VALUE

BR1 CBRHD-01 DIODE BRIDGE, SMDIP, CENTRAL 0.5A, 100V

BR2 CBRHD-01 DIODE BRIDGE, SMDIP, CENTRAL 0.5A, 100V

C1 CRCW08052492F RESISTOR 24.9K

C2 C0805C681F5GAC CAPACITOR, CER, CC0805, KEMET 680p, 50V

C3 NU

C4 C5750X7R2A475M CAPACITOR, CER, CC2220, TDK 4.7µF, 100V

C5 NU

C6 EEV-HA2A220P CAPACITOR, AL ELEC, PANASONIC 22µF, 100V

C7 C3216X5R0J106M CAPACITOR, CER, CC1206, TDK 10µF, 6.3V

C8 C3216X5R0J106M CAPACITOR, CER, CC1206, TDK 10µF, 6.3V

C9 C3216X5R0J106M CAPACITOR, CER, CC1206, TDK 10µF, 6.3V

C10 C3216X5R0J106M CAPACITOR, CER, CC1206, TDK 10µF, 6.3V

C15 C3216X5R0J106M CAPACITOR, CER, CC1206, TDK 10µF, 6.3V

C16 EMVY6R3ADA331MF80G CAPACITOR, AL ELEC, CHEMI-ON 330µF, 6.3V

C19 C2012X5R1C105K CAPACITOR, CER, CC0805, TDK 1.0µF, 16V

C20 C2012X5R1C474K CAPACITOR, CER, CC0805, TDK 0.47µF, 16V

C21 C0805C473K5RAC CAPACITOR, CER, CC0805, KEMET 47nF, 50V

C22 C0805C102K5RAC CAPACITOR, CER, CC0805, KEMET 1nF, 50V

C23 C0805C102K5RAC CAPACITOR, CER, CC0805, KEMET 1nF, 50V

C25 C0805C331K5RAC CAPACITOR, CER, CC0805, KEMET 330pF, 50V

C26 C0805C473K5RAC CAPACITOR, CER, CC0805, KEMET 47nF, 50V

C27 C3216X7R2A104K CAPACITOR, CER, CC1206, TDK 100nF, 100V

C28 C4532X7R3D222K CAPACITOR, CER, CC1812, TDK 2.2nF, 2 kV

C31 C0805C473K5RAC CAPACITOR, CER, CC0805, KEMET 47nF, 50V

D1 S3BB-13 DIODE, SMB, DIODE INC 3A, 100V

D2 NU

D3 CMR1U-01M DIODE, SMA, CENTRAL 1A, 100V

D4 CMHD4448 DIODE, SOD123, CENTRAL 125mA, 75V

D5 12CWQ03FN SCHOTTKY, TO252, IR 12A, 30V

D6 CMR1U-01M DIODE, SMA, CENTRAL 1A, 100V

D7 CMHD4448 DIODE, SOD123, CENTRAL 125mA, 75V

J1 RJ-45-8N-B RJ-45 CONNECTOR

J2 PJ-102A POWER JACK

J3 PJ-102A POWER JACK

J4 3104-2-00-01-00-00-080 POST, MILL MAX

J5 3104-2-00-01-00-00-080 POST, MILL MAX

L1 DO3308P-103MLD SM INDUCTOR, COILCRAFT 10µH

L3 DO1813P-331HC SM INDUCTOR, COILCRAFT 0.33µH

LED1 SSL-LXA228GC-TR11 LED,GREEN, LUMEX

P1 5012K-ND TEST POINT, KEYSTONE

P2 5012K-ND TEST POINT, KEYSTONE

P3 5012K-ND TEST POINT, KEYSTONE

P4 5012K-ND TEST POINT, KEYSTONE

Q1 SUD15N15-95 MOSFET, N-CH, TO252, VISHAY 150V, 15A

R1 CRCW2512200J RESISTOR 2Ω, 1W

LM5072 Evaluation Board Bill of Materials SNVA154A–March 2006–Revised May 2013

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Appendix A

Table 1. LM5072 Evaluation Board Bill of Materials (continued)

ITEM PART NUMBER DESCRIPTION VALUE

R2 CRCW2512200J RESISTOR 2Ω, 1W

R3 CRCW080520R0F RESISTOR 20Ω

R4 CRCW120610R0F RESISTOR 10Ω

R5 CRCW08053321F RESISTOR 3.3kΩ

R6 CRCW08051002F RESISTOR 10kΩ

R7 CRCW080510R0F RESISTOR 10Ω

R9 CRCW08051000F RESISTOR 100Ω

R11 CRCW08051002F RESISTOR 10kΩ

R12 CRCW08052432F RESISTOR 24.3kΩ

R13 CRCW08054991F RESISTOR 4.9kΩ

R14 CRCW12060R301F RESISTOR 0.301Ω

R15 CRCW12060R301F RESISTOR 0.301Ω

R16 CRCW08051001F RESISTOR 1kΩ

R17 CRCW08051001F RESISTOR 1kΩ

R18 CRCW08051472F RESISTOR 14.7kΩ

R19 NU

R20 CRCW08056340F RESISTOR 634Ω

R21 CRCW08052102F RESISTOR 21.0kΩ

R22 NU

R23 NU

R24 CRCW08050R0J RESISTOR 0Ω

R25 CRCW08050R0J RESISTOR 0Ω

R28 CRCW08053320F RESISTOR 332Ω

R29 CRCW08052492F RESISTOR 24.9kΩ

T1A DA2257-AL XFMR, FLYBACK, COILCRAFT 32µH

T1B DCT13EP-U12S005 XFMR, FLYBACK, TDK 32µH

U1 LM5072 POE PI AND PWM CTRL, TEXAS INSTRUMENTS LM5072

U2A PS2801-1-L OPTO-COUPLER, NEC PS2801

U2B PC3H7D OPTO-COUPLER, SHARP PC3H7D

U3 LMV431 REFERENCE, SOT23-3, TEXAS INSTRUMENTS LMV431

Z1 CMZ5944B Zener, 60V, CENTRAL CMZ5938B

Z2 SMAJ58A TVS, 58V, DIODE INC SMAJ58A

SNVA154A–March 2006–Revised May 2013 LM5072 Evaluation Board Bill of Materials

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Additional BOM to Add An 1A, 5.5V Output Rail

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A.1 Additional BOM to Add An 1A, 5.5V Output Rail

ITEM PART NUMBER DESCRIPTION VALUE

C12 C3216X5R1A106M CAPACITOR, CER, CC1206, TDK 10µF, 10V

C13 C3216X5R1A106M CAPACITOR, CER, CC1206, TDK 10µF, 10V

C14 C3216X5R1A106M CAPACITOR, CER, CC1206, TDK 10µF, 10V

C17 EMVY100ADA101MF55G CAPACITOR, AL ELEC, CHEMI-ON 100µF, 10V

D8 CMSH2-60 DIODE, SMA, CENTRAL 2A, 60V

J6 3104-2-00-01-00-00-080 POST, MILL MAX

J7 3104-2-00-01-00-00-080 POST, MILL MAX

L2 DO1813P-181MLD SM INDUCTOR, COILCRAFT 0.18µH

Z4 CMZ5920B ZENER, SMA, CENTRAL 6.2V

NOTE: The total load of the dual outputs should be limited below 10W maximum.

LM5072 Evaluation Board Bill of Materials SNVA154A–March 2006–Revised May 2013

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Texas Instruments AN-1455 LM5072 Evaluation Board (Rev. A) User guide

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